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Ebook Centrifugal Separations in Biotechnology PDF Full Chapter PDF
Ebook Centrifugal Separations in Biotechnology PDF Full Chapter PDF
Second Edition
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ISBN: 978-0-08-102634-2
1 Introduction 1
1.1 Introduction 1
1.1.1 Common Host Cells for Secreting Recombinant
Protein 6
1.1.2 Platform for Protein Expression 8
1.1.3 Extracellular Protein 9
1.1.4 Intracellular Protein—Liquid 9
1.1.5 Intracellular Protein—Inclusion Body 10
1.2 Centrifugal Separation and Filtration 12
1.2.1 Sedimenting Centrifuge 14
1.2.2 Filtering Centrifuges 15
1.3 Pros and Cons of Filtration Versus Centrifugation 16
1.4 Generic Flow Sheet for Biopharmaceutical Process 18
1.5 Other Centrifugal Separations 19
1.6 Inputs and Outputs of Centrifuge 19
1.7 Separation Metrics 20
1.7.1 Protein Yield 20
1.7.2 Centrate Suspended Solids 20
1.7.3 Throughput Rate 21
1.7.4 Cell Viability 21
1.8 Text Organization 22
1.9 Summary 23
References 23
Problems 25
v
vi CONTENTS
4 Disk Centrifuge 73
4.1 Lamella/Inclined Plate Settler 73
4.1.1 Inclined Plate Settler Principle 73
4.1.2 Complications in Inclined Plate Settler 74
CONTENTS vii
xvii
Preface to Second Edition (2019)
xix
xx PREFACE TO SECOND EDITION (2019)
xxiii
xxiv PREFACE TO FIRST EDITION (2007)
interested. Readers who are not interested in modeling can jump directly
to Chapter 13. The Le number provides a basis for the scale-up and per-
formance prediction covered in Chapter 13. Here, numerous examples
are used to demonstrate the versatility of the numerical simulator built on
the Le-approach to forecast performance in parallel with concurrent test-
ing, which is often limited for various reasons. Numerical simulation can
also be used to analyze laboratory, pilot, and production test results to
validate machine and process performance. Therefore numerical simula-
tion can be used for laboratory screening, pilot testing, clinical
manufacturing testing, full-scale production testing, and even for small-
scale testing in the laboratory to investigate alternatives and improve-
ments of the existing process under production. Membrane processes,
such as microfiltration, ultrafiltration, and diafiltration, are frequently
used in bioseparation. Lastly, Chapter 14 is devoted to combining two
separation processes: centrifugation and membrane separation. Two
examples, respectively, on centrifugal filter in spintube and large rotating
membrane systems are discussed. The general approach can be extended
to other rotating membrane geometry.
Centrifugation has been treated as a black box in the past, as the sub-
ject is quite complex and nonintuitive. The subject involves multiple dis-
ciplines, such as fluid dynamics, mechanics and vibration, design,
material science, rheology, chemical and process engineering, chemistry,
biology, and physics. I hope this text will fulfill the quest of knowledge
rendering centrifuge a lot more “transparent” to biologists, biotechnolo-
gists, chemists, physicists, scientists, researchers, and practicing engi-
neers. The more they know the better they can deploy, comfortably and
without reservation, centrifuge as handy process equipment.
Problems are listed at the end of each chapter in the text, and they
complement and supplement the contents in the chapter. They are also
meant to reinforce the concept for the readers through practices, chal-
lenging their thoughts and understanding on the topic. Apart from practi-
tioners and researchers, this book is written primarily for 4th year
university student in the 4-year undergraduate study and research gradu-
ates in their MS or PhD research program in university taking biosepara-
tion, bioprocessing, advanced unit-operation/process engineering, or
similar courses.
I am grateful to Stella, Jessica, Jeffrey, my mother, and my late father
for putting up with me while I was devoted to preparing this book. Both
my late father and my dear friend and mentor, the late Professor Ascher
H. Shapiro, demonstrated dedication and perseverance in their lives,
which inspired me all along, especially during the trying times when I
xxvi PREFACE TO FIRST EDITION (2007)
1.1 Introduction
Biotechnology has revolutionized our life in the 20th century [1]. Its
impact is only now being felt from engineering food [2 4], engineering
and delivering drugs [5,6], to engineering consumable products. Without
doubt it will continue to influence our daily lives for years to come. One
of the many successful examples is that drugs, such as monoclonal anti-
bodies (mAbs) and some basic drug substances (i.e., the building block
for various drugs), can now be manufactured and formulated from bior-
eaction. One of the commonly used methods in biotechnology is the
recombinant DNA technique [7 9]. A desired gene is isolated from one
organism, and this is inserted into a small piece of carrier DNA called a
vector. It is highly desirable that the recombined DNA (vector plus
gene) can propagate in a similar or unrelated host/recipient cell.
The mammalian cell, such as the Chinese Hamster Ovary cell, is a
popular host cell. Fig. 1.1 shows a schematic of an animal cell which is
very similar to that of a mammalian cell. A characteristic size of the
mammalian cell is about 10 20 µm. Unlike a plant cell, there is no cell
wall for animal and mammalian cells, so they rely on a plasma mem-
brane to keep the intracellular contents intact. High shear stress acting
on the cell can rupture the fragile membrane releasing the intracellular
material.
Yeast (see schematic in Fig. 1.2), in eukaryotic single-celled microor-
ganisms classified as a member of fungus kingdom, has been commonly
used as a host cell in the recombinant DNA process, the knowledge and
experience of which we have gained from the brewery industry. Unlike
a mammalian cell, the yeast cell has a strong cell wall. Yeast cells are
smaller than mammalian cells and are typically between 7 and 10 µm.
Some common yeast hosts include, Saccharomyces cerevisiae (referred
commonly as baker yeast) and Pichia pastoris.
Bacteria, such as Escherichia coli (hereafter abbreviated as E. coli)
and Bacillus subtilis, have been used as host cells for the recombinant
Figure 1.2 Yeast cell schematic showing both cell wall and membrane.
Introduction 3
therapeutics. For example, mAb has been a popular antibody made in the
laboratory used for cancer treatment where the antibody is designed to
attach as a label to their counterpart protein (antigen) on a specific cancer
cell so that immune cells can spot and attack the cancer cells. As an
example, the mAb known commercially as alemtuzumab drug (note all
mAb drugs have the last three alphabets labeled as “mab,” which distin-
guishes them being mAb-based drugs) can target at the antigen CD52
found on the cancer cells that causes chronic lymphocytic leukemia [12].
As antigens are discovered to be linked to more specific cancers, more
mAbs have also been developed for cancer treatment. Some mAbs work
better on certain cancers than others. mAb can also attach to the antigen
on breast cancer cells blocking the growth of breast cancer cells.
Cancer cells can “turn off the switch” of immune cells to avoid being
attacked by the immune system in our bodies. Inhibitors, or commonly
known as checkpoints, are mAb produced by the recombinant protein
process, that inhibit the protein secreted from the cancer cells in “fool-
ing” the immune cells, thereby allowing the immune cells to carry out
their normal functions. As an example, PD-1 is a protein on the immune
T-cells. The immune T-cells are normally in a switch-off condition
because PD-1 has been attached by their counterpart PD-L1, another
protein that both normal cells and cancer cells have. In other words,
they have been switched off. Some cancer cells have an abundant PD-
L1 that is used to attach to the PD-1 of the immune T-cells thereby
evading being attacked. On the other hand, mAb can target at either PD-
1 or PD-L1 and inhibit their binding, thereby allowing the immune cells
to attack the cancer cells. For example, pembrolizumab is a PD-1 inhibi-
tor that can treat skin melanoma, non-small-cell lung cancer, kidney can-
cer, bladder cancer, head and neck cancer, and Hodhkin lymphoma [12].
As another example, atezolizumab is a PD-L1 inhibitor that can treat
bladder cancer, non-small-cell lung cancer, and Merkel cell carcinoma
[12]. New inhibitors are being developed rapidly over time as more
knowledge is being gained on the specifics of different cancers and their
behavior. The examples mentioned in the forgoing are just a few under
the broad umbrella of immunotherapy for which mAb plays an impor-
tant role. The main objective of immunotherapy is to enable the immune
system of patients to recognize or target specific cancer cells and destroy
them [13]. In 2005 the total mAb therapeutics entering first-in-human
studies per year is 35, 16 out of which are for cancer treatment. In 2017
the total mAb therapeutics rose to 105, and nearly 80 were for cancer
treatment. Indeed, the antibody therapeutics entering clinical study and
being approved are in record numbers [14].
Introduction 5
the difference in the two densities, it takes a very long time to separate,
translating in simple terms—to an impractically low-capacity, high-cost
operation. On the other hand, separation by sedimentation can be much
enhanced under centrifugal acceleration. This is possible by introducing
the suspension with biomass in a centrifuge rotating at high speed where
centrifugal acceleration can be hundreds to millions of times that of the
Earth’s gravitational acceleration.
(A)
Fermentation
and bioreaction
Mammalian
cell Bacteria Yeast
Centrifuge Centrifuge
Lysing
separation clarification
Centrifuge/filter
IB washing
polishing
Downstream processing
(B) Recombinant
protein expression
IB
Protein
Cell Cell
Cell
broth during maturity without the need of cell lysis. With the advent of
new research and technology, it is expected that more new recombinant
processes and new host cells will be discovered over time. Regardless,
we can look at these protein expression processes being the “model” for
downstream processes, including separation, which is a key step
upstream of purification, whether it be extracellular or intracellular pro-
tein or even a hybrid of both. Without achieving the objective in separa-
tion, the steps downstream of separation will only become more difficult
leading to poor protein recovery and low yield. Below, we will briefly
describe each of these expression processes and the downstream flow
sheet in general terms.
(C)
Cell culture/
fermentation
Clarification and
Cell cell separation
(centrifugation)
Protein
Washing and
concentration
(diafiltration,
ultrafiltration)
Purification
(chromatography)
(D)
Fermentation/
cell culture
Cell harvest
Cell lysis
Protein
Cell
Lysate
clarification
For example (centrifugation)
enzymes,
growth,
factors,
vaccines Fine
separation,
washing,
concentration
Purification
(chromatography)
(E)
Fermentation
IB
Cell harvest
Cell
Cell lysis
Classification
Inclusion bodies and
cell debris
(centrifugation)
Solubilization,
Solubilization Refolding refolding
Purification
(chromatography)
The IB cells are washed and centrifuged a few times before sending
to the next process step. There the IB cells are solubilized moderately
by alkaline-based chemicals to dissolve the protein IB. Subsequently the
misfolded protein is refolded to restore the bioactivity of the protein.
The protein in liquid is subsequently purified in chromatography. If clas-
sification of the IB cells and cell debris is not carried out properly by
centrifugation, cell debris will be carried downstream causing contami-
nation and fouling of the chromatography column. On the other hand,
IB cells which have not been separated by centrifugation and leave the
centrate also represent a loss of yield for the entire process. The process
flow sheet is summarized in Fig. 1.4E.
greater than the Earth’s gravity. A density difference between the solid
and the liquid phase is required to affect separation. A schematic of a
sedimenting solid-wall centrifuge is shown in Fig. 1.5. Similarly, a ligh-
ter dispersed solid phase, like fat or solids with attached air bubbles, can
also float (instead of sink) in a continuous liquid phase, and separation
by flotation can be enhanced in a centrifugal field.
On the other hand, density difference between the two phases is not
required to separate the solid from liquid phase in a filtering centrifuge.
Both phases are driven under the centrifugal body force to the perforated
wall lined with a filter medium. Liquid permeates (see Fig. 1.6) through
the filter medium while solids, comparable or larger than the openings
of the filter medium, are retained. Sometimes even smaller solids can be
retained as they “bridge across” or “jam” the medium openings preclud-
ing them from filtering through. As such, openings in the filter medium
can be selected normally two to three times larger than the particle size
to be retained. Once a “cake” layer of particles forms on the medium
despite some smaller particles that may still percolate through during
initial filtration, the cake layer further acts as a frontline filter medium
in series with the original medium to retain the incoming particles.
Slurry pool
Axis
Solid wall
Cake
Cake
Axis Filtrate
It can be seen that filtering centrifuges can separate particles and liquid
regardless of their density difference; this is very much different from a
sedimenting centrifuge that relies on the density difference of the two
phases to drive separation.
Sedimenting
centrifuge
Batch Continuous
discharge discharge
Continuous
Batch feed Disk Decanter
feed
Dropping- Conventional
Spintube Tubular
bottom disk decanter
Solid Nozzle
basket decanter
acceleration and the sediment is stored temporarily in the bowl until the
quality of the separated liquid gets affected by the growing sediment in
the bowl. At that point, feeding stops, the centrifuge is allowed to coast
down, the liquid pool is drained, and the sediment is removed. The cen-
trifuge needs to be cleaned before the next cycle.
For continuous or semicontinuous discharge of sediment, both disk
and decanter centrifuges fall in this category. Under disk centrifuge,
there are two types depending on how the concentrated solids are dis-
charged—dropping bottom with intermittent solid discharge, and the
nozzle disk with continuous solid discharge. On the other hand, there
are four types under decanter, a conventional decanter, dual-cone
decanter for classifying two solids and a liquid phase, compound beach
decanter for dewatering fine solids producing a paste-like cake [27], and
nozzle decanter for classifying kaolin suspension with 1 2 µm particles.
Filtering
centrifuge
Batch Continuous
discharge discharge
Peeler and
Centrifugal Multistage Insitu cake Vibrating
siphon
filter pusher washing screen
basket
Inverting-
Tumbling
bag
screen
basket
Wide-angle
screen
When the product protein is in the solids, such as in the biological cells,
filter aid should not be used as it is almost impossible to separate the fil-
ter aid from the valuable biological material.
actually generates less shear stress than tangential flow filtration con-
trary to conventional wisdom, provided a good feed acceleration is
adopted in the centrifuge, see Chapter 4, Disk Centrifuge. Also, centrifu-
gation does not suffer from the fouling of membrane that leads to costly
membrane replacement and downtime. Also, it is a very robust and reli-
able system.
The solids in suspension for the process of interest are very small, in
the domain of 10 µm and below, and sometimes even in the 1 2 2 µm
range. While the small density difference affects sedimentation and not
as much for filtration, as discussed, the fine biosolids affect depth filtra-
tion, clogging flow path of the filter, leading to rapid large pressure drop
across the depth filter. For microfiltration, the membrane needs to be
stayed “unclogged” or “unfouled” by the use of a crossflow using a high
shear rate to scour the membrane surface (see Chapter 14: Rotating
Membrane in Bioseparation) and to use cleaning agent to wash the
membrane during downtime. Also, diafiltration helps to maintain a
lower solid concentration, to prevent fouling. Nevertheless, fouling lead-
ing to the replacement of membrane and an associated downtime are the
key drawbacks of microfiltration in this application. In addition, a much
larger volume of liquid product (two to four times the original volume)
results from washing or diafiltration to recover the protein. This implies
a higher cost for the process as it involves more concentration by ultra-
filtration and other processes downstream for treating the spent liquid.
A fourth possibility is to combine centrifugation with depth
filtration as an integrated approach to separate mammalian cells.
Centrifugation takes up the solids loading from the feed stream leaving
18 Centrifugal Separations in Biotechnology
Bioreactor/
cell culture
Concentration,
Purification
Coarse and buffer Sterile Drug
Centrifugation (chromatography)
fine filtration exchange filtration substance
(UF/DF)
Fermenter
Centrate/effluent/
Feed Centrifuge overflow liquid
Concentrate/cake/
underflow solids
product can be in the fine suspended solids, such as the IBs, crystals or
precipitants containing protein, or in the centrate liquid phase, as in the
extracellular protein expression (yeast and mammalian cells). The centri-
fuge needs to be tuned to separate the product from the rest (waste or
recycle stream). Depending on the specific process, as discussed below,
some metrics or measures are commonly used to assess the centrifugal
separation.
EPOCH IV.
CHAPTER I.